Broan B6BW Installation guide

Vertical Wall Mount Air Handler

Please read all information in this manual thoroughly and become familiar with the capabilities

and use of your appliance before attempting to operate or maintain this unit. These instructions

are primarily intended to assist qualiﬁ ed individuals experienced in the proper installation of

this appliance. Some local codes require licensed installation/service personnel for this type

of equipment. Improper installation, service, adjustment, or maintenance may cause explosion,

ﬁ re, electrical shock or other hazardous conditions which may result in personal injury or

property damage.

Unless otherwise noted in these instructions, only factory authorized kits or accessories may

be used with this product. Keep this manual where you have easy access to it in the future. If a

problem occurs, check the instructions and follow recommendations given. If these suggestions

don’t eliminate your problem, call your servicing contractor.

DO NOT DESTROY. PLEASE READ CAREFULLY AND

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

IMPORTANT

B6BW Series

INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS

Important Safety Information ....................................2

Requirements & Codes ..............................................3

General Information ...................................................4

Before You Install this Unit .........................................4

Locating the Air Handler ............................................4

Minimum Clearances .................................................5

Operation of Air Handler During Construction ...........4

Installation in a Garage .............................................5

Plenums & Air Ducts .................................................5

Acoustical Duct Work .............................................5

Unconditioned Spaces ...........................................5

Filter Requirements ...................................................5

Air Handler Installation ..............................................6

Packaging Removal ...................................................6

Mounting Applications ...............................................6

Connecting Refrigerant Tubing ..................................6

System Depressurization .......................................7

Connecting the Linsets ..........................................7

Condensate Drainage ..............................................7

Electrical Wiring ..........................................................7

Line Voltage ...............................................................8

Grounding..................................................................9

Thermostat Connections ...........................................9

Conﬁ guring Blower Speed for Multi Speed Units ....10

Selecting Continuous Low Speed Fan Operation ....10

Startup & Adjustments ............................................11

Before You Start the Unit .........................................11

Refrigerant Charging ...............................................11

Unit Maintenance ......................................................12

Troubleshooting ........................................................12

Figures & Tables .......................................................13

Figure 4. B6BW Physical Dimensions ..................13

Table 6. B6BW Speciﬁ cations ..............................13

Table 7. Blower Performance Data .......................14

Wiring Diagrams ......................................................15

Figure 5. B6BW 5KW (1.5, 2, & 2.5 Ton) ..............15

Figure 6. B6BW 8KW/10KW (1.5, 2, & 2.5 Ton) ...16

Figure 7. B6BW 5KW/036 (3 Ton) ........................17

Figure 8. B6BW 8KW/10KW (3 Ton) ....................18

Location of Air Handler Components ......................19

Figure 9. Air Handler Components .......................19

Installation / Performance Checklist .......................20

IMPORTANT SAFETY INFORMATION

INSTALLER: Please read all instructions before servicing

this equipment. Pay attention to all safety warnings and

any other special notes highlighted in the manual. Safety

markings are used frequently throughout this manual to

designate a degree or level of seriousness and should not

be ignored. WARNING indicates a potentially hazardous

situation that if not avoided, could result in personal injury

or death. CAUTION indicates a potentially hazardous

situation that if not avoided, may result in minor or moderate

injury or property damage.

WARNING:

B6BW Air Handlers leave the factory with a

nitrogen holding charge. Use caution when

preparing coils for ﬁ eld connections. If repairs

make it necessary for evacuation and charging,

it should only be attempted by qualified,

trained personnel thoroughly familiar with this

equipment. Some local codes require licensed

installation service personnel to service this

type of equipment. Under no circumstances

should the equipment owner attempt to install

and/or service this equipment. Failure to comply

with this warning could result in equipment

damage, personal injury, or death.

NITROGEN

HEALTH

FLAMMABILITY

REACTIVITY

0 Minimal Hazard

1 Slight Hazard

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

Improper servicing could result in dangerous

operation, serious injury, death or property

damage.

• Before servicing, disconnect all electrical power

to air handler.

• When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

REQUIREMENTS & CODES

WARNING:

This unit must be installed in accordance with

instructions outlined in this manual during

the installation, service, and operation of

this unit. Unqualiﬁ ed individuals should not

attempt to interpret these instructions or

install this equipment. Failure to follow safety

recommendations could result in possible

damage to the equipment, serious personal

injury or death.

• The installer must comply with all local codes and

regulations which govern the installation of this type

of equipment. Local codes and regulations take

precedence over any recommendations contained in

these instructions. Consult local building codes and the

National Electrical Code (ANSI CI) for special installation

requirements.

• This equipment contains nitrogen gas. Installation or

servicing should only be performed by qualiﬁ ed trained

personnel thoroughly familiar with this type equipment.

• All electrical wiring must be completed in accordance

with local, state and national codes and regulations

and with the National Electric Code (ANSI/NFPA 70)

or in Canada the Canadian Electric Code Part 1 CSA

C.22.1.

• Installation of equipment may require brazing operations.

Installer must comply with safety codes and wear

appropriate safety equipment (safety glasses, work

gloves, ﬁ re extinguisher, etc.) when performing brazing

operations.

• Install this unit only in a location and position as speciﬁ ed

on pages 4 & 5. This unit is designed only for Indoor

installations and should be located with consideration

of minimizing the length of the supply and return ducts.

See Table 7 (page 14) and the rating plate for proper

circulating airﬂ ow data.

• Follow all precautions in the literature, on tags, and

on labels provided with the equipment. Read and

thoroughly understand the instructions provided with

the equipment prior to performing the installation and

operational checkout of the equipment.

• This air handler may be used for temporary heating

of buildings or structures under construction. See the

guidelines listed on page 4.

• Air handler installations in a residential garage must be

installed as speciﬁ ed on page 5.

The information listed below is for reference purposes only

and does not necessarily have jurisdiction over local or state

codes. Always consult with local authorities before installing

any gas appliance.

Duct Systems

• US and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning

Contractors National Association (SMACNA), or American

Society of Heating, Refrigeration, and Air Conditioning

Engineers (ASHRAE) Fundamentals Handbook

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70

• CANADA: Canadian Electrical Code CSA C22.1

General Installation

• US: Current edition of the NFGC and the NFPA 90B. For

copies, contact the National Fire Protection Association

Inc., Batterymarch Park, Quincy, MA 02269; or American

Gas Association, 400 N. Capitol, N.W., Washington DC

20001 or www.NFPA.org

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke

(Toronto), Ontario, M9W 1R3 Canada

Safety

• US: (NFGC) NFPA 54–1999/ANSI Z223.1 and the

Installation Standards, Warm Air Heating and Air

Conditioning Systems ANSI/NFPA 90B.

• CANADA: CAN/CGA-B149.1 and .2–M00 National

Standard of Canada. (NSCNGPIC)

GENERAL INFORMATION

This appliance has been tested for capacity and efﬁ ciency

in accordance with A.R.I. Standards and will provide

many years of safe and dependable comfort, providing

it is properly installed and maintained. Abuse, improper

use, and/or improper maintenance can shorten the life

of the appliance and create unsafe hazards. Please read

all instructions before installing the unit.

Before You Install this Unit

 This equipment is securely packaged at the time of

shipment and upon arrival should be carefully inspected

for damage prior to installing the equipment at the job

site. Claims for damage (apparent or concealed) should

be ﬁ led immediately with the carrier.

 The cooling load of the area to be conditioned must be

calculated and a system of the proper capacity selected.

It is recommended that the area to be conditioned be

completely insulated and vapor sealed.

 Check the electrical supply and verify the power supply

is adequate for unit operation. The system must be wired

and provided with circuit protection in accordance with

local building codes. If there is any question concerning

the power supply, contact the local power company.

 Verify the air delivery of the air handler is adequate to

handle the static pressure drop of the coil, ﬁ lter, and

duct work.

Table 1. Minimum Unit Clearances

INSTALLATION CLEARANCES

Left Side ......... 0 Inches Right Side ...... 0 Inches

Back ...............0 Inches

Front ...........

†

See Notes

†

NOTES:

Alcove Installations - Allow 24 in. minimum clearance

from front of unit to nearest wall or partition for servicing.

Recommended clearance is 36 in.

Closet installations - require a return air grill installed in

the door or a partially louvered door across the opening

for proper air circulation. For clearances 6” or greater, the

closet must have an open free area of 235 in

minimum.

For special clearances between 1” - 5”, requirements

are a louvered door with a minimum of 250 in

(1613

) free area. A fully louvered closet door is strongly

recommended for both installation types.

REAR

RIGHT

SIDE

LEFT

SIDE

FRONT

Locating the Air Handler

• Survey the job site to determine the best location for

mounting the unit. Consideration should be given to

availability of electric power, service access, and noise.

• The dimensions of the room or alcove must be able

to accommodate the overall size of the unit and the

installation clearances listed in Table 1. Physical

dimensions for this air handler are also shown in Figure

4 (page 13).

• The air handler should be installed before routing the

refrigerant tubing.

Minimum Clearances

• This appliance must be installed in accordance with

clearances listed in Table 1. The air handler must be

installed with ample clearance for easy access to the

air ﬁ lter, blower assembly, burner assembly, controls,

and vent connections.

• Sufﬁ cient clearance for unobstructed airﬂ ow through a

louvered door must be maintained in order to achieve

rated performance.

Operation of Air Handler During Construction

CAUTION:

Failure to follow these instructions will void the

factory warranty and may signiﬁ cantly reduce

the life or the performance of the air handler,

and/or result in other unsafe conditions. It is

the responsibility of the installing contractor

to insure these provisions are met.

Operating an air handler in a construction environment

can cause the appliance a variety of problems. Proper

use of commercial portable space heating equipment

during construction is recommended. This air handler

may be used during construction if it is not in violation of

any applicable codes and the following criteria are met:

• The installation (including electrical supply, gas supply,

and duct work), must meet all applicable codes and

be permanently installed according to the instructions

supplied with the air handler.

• The air handler must be controlled by a properly installed

thermostat that complies with the current provisions

of the NEC (ANSI/NFPA 70) and all applicable codes

having jurisdiction. Thermostat connections must be

made in accordance with instructions supplied with the

air handler and thermostat.

• The installation must include a properly installed ﬁ lter in

the return air system with no by-pass air. The ﬁ lter must

be inspected frequently and replaced when necessary.

• Return air must be supplied unrestricted and located

such that dust and gases from construction activity are

not introduced into the circulating air system.

• Before occupying the structure: The ﬁ lter must be

replaced or cleaned, the duct work must be inspected

and cleaned of any construction debris, and the furnace

must be cleaned and/or repaired if found to be dirty,

damaged, or malfunctioning in any way by a qualiﬁ ed

HVAC technician. The air handler shall be inspected

and approved by applicable local authority even if this

requires redundant inspections.

• The serial number for the air handler used during

construction must be submitted in writing (fax and

email also acceptable). This information will be used to

track the long-term affects of air handler usage during

construction. Proof of this submittal shall be available for

the ﬁ nal inspection of the air handler prior to occupancy.

Installation in a Garage

WARNING:

Do not place combustible materials on or against

the cabinet. Do not place ﬂ ammable materials,

(gasoline, paint thinners, etc.) or any other

ﬂ ammable vapors and liquids, in the vicinity

of the air handler.

The B6BW air handler may be installed in a residential

garage with the provision that the unit must be located or

protected to prevent physical damage by vehicles.

Standard for the Installation of Warm Air Heating and

Air Conditioning Systems (NFPA No. 90B).

• Design the duct work according to methods described

by the Air Conditioning Contractors of America (ACCA).

• The return air duct must have the same free area as

the opening provided on the blower coil unit.

• The ducts should be appropriately sized to the capacity

of the air handler to ensure its proper airﬂ ow rating.

• It is good practice to seal all connections and joints

with industrial grade sealing tape or liquid sealant.

Requirements for sealing ducts vary from region to

region. Consult with local codes for requirements speciﬁ c

to your area.

Acoustical Duct Work

Certain installations may require the use of acoustical

lining inside the supply duct work.

• Acoustical insulation must be in accordance with the

current revision of the Sheet Metal and Air Conditioning

Contractors National Association (SMACNA) application

standard for duct liners.

• Duct lining must be UL classiﬁ ed batts or blankets with

a ﬁ re hazard classiﬁ cation of FHC-25/50 or less.

• Fiber duct work may be used in place of internal duct

liners if the ﬁ ber duct work is in accordance with the

current revision of the SMACNA construction standard

on ﬁ brous glass ducts. Fibrous duct work and internal

acoustical lining must be NFPA Class 1 air ducts when

tested per UL Standard 181 for Class 1 ducts.

Unconditioned Spaces

All duct work passing through unconditioned space must

be properly insulated to minimize duct losses and prevent

condensation. Use insulation with an outer vapor barrier.

Refer to local codes for insulation material requirements.

Filter Requirements

B6BW Air Handlers are supplied with a single air ﬁ lter

when shipped from the factory. Accessing the ﬁ lter does

not require tools and can be removed from the front of

the unit. See Unit Maintenance (page 12) for ﬁ lter sizes

and installation information.

WARNING:

Never operate the furnace without a ﬁ lter in

place. Dust and lint can build up on internal

components, resulting in loss of efﬁ ciency,

equipment damage, and possible ﬁ re.

Plenums & Air Ducts

This unit is designed only for use with a supply and return

duct. Air ducts should be installed in accordance with the

standards of the National Fire Protection Association

Standard for Installation of Air Conditioning Systems

(NFPA 90A), Standard for Installation of Residence Type

Warm Air Heating and Air Conditioning Systems (NFPA

90B), and all applicable local codes. NFPA publications

are available by writing to: National Fire Protection

Association, Batterymarch Park, Quincy, ME 02269 or visit

www.NFPA.org on the web.

WARNING:

All return ducts must be secured to the air

handler with sheet metal screws. All return

ducts must be adequately sealed. When return

air is provided through the bottom of the unit,

the joint between the air handler and the return

air plenum must be air tight.

Return air and circulating air ducts must not be

connected to any other heat producing device

such as a ﬁ replace insert, stove, etc. This may

result in ﬁ re, explosion, carbon monoxide

poisoning, personal injury, or property damage.

• Plenums and air ducts must be installed in accordance

with the Standard for the Installation of Air Conditioning

and Ventilating Systems (NFPA No. 90A) or the

AIR HANDLER INSTALLATION

The B6BW Air Handler is shipped ready for vertical upﬂ ow

installation and can be mounted directly on a wall or

recessed between framing studs as shown in Figure 1 .

Units are also approved for closet or alcove installation

with zero clearance to combustibles. See Table 1 (page

4) for required installation clearances. This appliance is

only for indoor use.

• The unit must be leveled at installation and attached to

a properly installed duct system.

• The surface that the air handler is mounted on must

provide sound physical support of the unit.

• The air handler must be installed so that all electrical

components are protected from water.

• If a louvered door is installed across the front of this

unit, the appliance must be mounted ﬂ ush or behind

front edge of ﬁ nished wall. See Figure 1.

Packaging Removal

Remove the shipping crate and User’s Manual from the

equipment. Take care not to damage the tubing connections

when removing the crate.

Mounting Applications

Units have a bottom and/or front return. Units are shipped

for installation in a front return application. Front close-

off panel (if supplied) may be discarded. If installed in a

bottom return application, attach bottom access panel to

the front of the unit below the top service panel.

NITROGEN

HEALTH

FLAMMABILITY

REACTIVITY

0 Minimal Hazard

1 Slight Hazard

If the air handler is recessed in a wall, attachment to the

framing studs are through the inside of the front ﬂ ange.

For hanging applications, these units are provided with

2-piece offset hanging bracket (Figure 1) attached to the

rear of the cabinet. Mounting bracket dimensions are

shown in Figure 4 (page 13).

Connecting Refrigerant Tubing

WARNING:

Evaporator Coils are factory shipped with a

nitrogen charge. Avoid direct face exposure

or contact with valve when gas is escaping.

Always ensure adequate ventilation is present

during the depressurization process. Address

any uncertainties before proceeding. Failure

to comply with this warning could result in

equipment damage, personal injury, or death.

18"

(457 mm)

24” Clearance from

nearest wall or

partition

Full Louvered

Door

Wall

Mount

Closet

Installation

Alcove

Installation

6”

(152mm)

Typical Closet Door

with Return Air Grill

Installed

Recessed

Wall

2-Piece

Mounting

Bracket

24” Clearance from

nearest wall or

partition

Figure 1. Unit Installation

CAUTION:

This unit uses refrigerant R-410A. DO NOT use

any other refrigerant in this unit. Use of another

refrigerant will damage the unit.

• Every effort should be made by the installer to ensure

that the ﬁ eld installed refrigerant containing components

of the system have been installed in accordance with

these instructions and sound installation practices to

insure reliable system operation and longevity.

• Always refer to the installation instructions supplied with

the outdoor unit for piping requirements. The suction

and liquid lines must be sized in accordance with the

condensing unit speciﬁ cations. See Figure 4 (page 13)

for liquid and suction line locations.

• When connecting refrigerant linesets together, it is

recommended that dry nitrogen be ﬂ owing through the

joints during brazing. This will prevent internal oxidation

and scaling from occurring.

• Refrigerant tubing should be routed in a manner that

minimizes the length of tubing and the number of bends

in the tubing. It should be supported in a manner that

prevents it from vibrating or abrading during system

operation. Tubing should be kept clean of foreign debris

during installation.

• If precise forming of refrigerant lines is required, a copper

tubing bender is recommended. Avoid sharp bends and

contact of the refrigerant lines with metal surfaces.

• Refrigerant lines should be wrapped with pressure

sensitive neoprene or other suitable material where

they pass against sharply edged sheet metal.

CAUTION:

Before brazing the B6BW, remove the core from

the service port. Failure to comply may result in

leakage at the service valve. Replace the core

and cap once brazing is complete.

• The B6BW air handler is charged through service valves

on the end of the liquid tube for each circuit. These must

be removed before brazing the line sets.

System Depressurization

1. Remove the cap from the end of the liquid line.

2. Verify pressurization by depressing the Schrader valve

on the end of the liquid line. Listen for any escaping gas.

If there is no pressure, test the unit for leakage.

• If leakage is found, clearly mark the location of the leak

and return the unit to the distributor for processing.

• If no leaks are found, the air handler may be installed.

3. Depress the valve to relieve all pressure from the coil.

Connecting the Linesets

Notes: Before proceeding, perform steps 1 - 3 in the

System Depressurization section.

1. Route and cut both lineset tubes to proper length in

accordance with the outdoor unit speciﬁ cations. Verify

the ends are round, clean, and free of any burrs.

2. Connect the suction and liquid lineset tubes.

CAUTION:

It is recommended that a wet rag be wrapped

around the suction line before applying heat.

Failure to keep components cool during brazing

may result in structural damage, premature

equipment failure, or possible personal injury.

3. Braze the individual connections with dry nitrogen ﬂ owing

through the joints. This will prevent internal oxidation

and scaling from occurring.

4. Wrap the refrigerant lines with pressure sensitive

neoprene or other suitable material especially where

the lines enter the opening in the sheet metal.

5. Evacuate the system of moisture and non-condensables

to prevent low efﬁ ciency operation or damage to the

unit. The suggested range of evacuation is 250 - 500

microns.

6. Charge the system with refrigerant. Refer to the

outdoor unit installation manual for additional charging

instructions.

7. Check the system for leaks, including the lineset and the

brazed joints. NOTE: Apply a soap and water solution on

each joint or union with a small paintbrush. If bubbling

is observed, the connection is not adequately sealed.

8. Properly dispose of all removed parts.

Condensate Drainage

The drain pan that is supplied with this air handler contains

a primary and secondary drain ﬁ tting. The condensate is

drained from the unit through two 3/4” male pipe ﬁ ttings

located on the front side of the unit as shown in Figure

2 (page 8).

CAUTION:

The air handler must be level to ensure proper

condensate drainage. An unlevel installation

may result in structural damage, premature

equipment failure, or possible personal injury.

• The method for disposing of condensate varies according

to local codes. Consult your local code or authority

having jurisdiction.

• The drain lines can be routed out the bottom, left or right

side of the air handler, but must maintain a downward

slope to ensure proper condensate drainage. If the

bottom access panel is moved to the front (for bottom

return air), the condensate drain tubes must be routed

Rubber

Washers

Side Drainage

Bottom Drainage

1/2” I.D.

Drain Tubes

3/4” NPT Adapters

w/ 1/2” Hose Barb

NOTES:

1. Field supplied drain lines must be looped to form a trap.

2. Drain lines must be routed to the outside of the cabinet.

3. Avoid sharp bends and pinching of the tubing.

Knockouts for condensate drain tubes

(bottom, left, or right side of unit

Primary & Secondary

Drain Locations

See Notes

Figure 2. Condensate Drainage

thru one of the side openings. DO NOT route the

condensate drain tubes thru the front panel.

• Drain pan MUST be drained with ﬁ eld supplied tubing and

looped to form a trap. Failure to install a trap could result

in condensation overﬂ owing the drain pan, resulting in

substantial water damage to surrounding area. Both

drains must be trapped separately. See Figure 2.

• It is recommended that both drain tubes have a minimum

internal diameter of 1/2” and be separately routed to

a suitable drain, avoiding sharp bends and pinching of

the lines. Refer to local codes and restrictions for proper

condensate disposal requirements.

• Both adapters should be made of PVC or similar

material and contain a rubber washer. Hand tightened

the adapters to the drain pan. DO NOT use pliers or

any other tools. Overtightening may crack the drain

pan and cause condensate to leak.

• During system checkout, inspect the drain line and

connections to verify proper condensate drainage.

ELECTRICAL WIRING

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

Improper servicing could result in dangerous

operation, serious injury, death or property

damage.

• Before servicing, disconnect all electrical power

to air handler.

• When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

• Electrical connections must be in compliance with

all applicable local codes and ordinances, and with

the current revision of the National Electric Code

(ANSI/NFPA 70).

• For Canadian installations, the electrical connections

and grounding shall comply with the current Canadian

Electrical Code (CSA C22.1 and/or local codes).

Line Voltage

• An electrical disconnect must be located within sight

of and readily accessible to the unit. This switch shall

be capable of electrically de-energizing the outdoor unit.

See unit data label for proper incoming ﬁ eld wiring. Any

other wiring methods must be acceptable to authority

having jurisdiction.

• It is recommended that the line voltage to the unit be

supplied from a dedicated branch circuit containing the

correct fuse or circuit breaker for the unit.

• Overcurrent protection must be provided at the branch

circuit distribution panel and sized as shown on the unit

rating label and according to applicable local codes. See

the unit rating plate and Table 2 (page 9) for maximum

circuit ampacity and maximum overcurrent protection

limits.

• Refer to the unit wiring label for proper high and low

voltage wiring.

• Use only copper wire for the line voltage power supply

to this unit. Use proper code agency listed conduit and

a conduit connector for connecting the supply wires to

the unit.

• If replacing any of the original wires supplied with the

unit, the replacement wire must be copper wire consisting

of the same gauge and temperature rating.

• Provide power supply for the unit in accordance with

the unit wiring diagram, and the unit rating plate. The

installer should become familiar with the wiring diagram/

schematic before making any electrical connections to

the unit. See Figures 5 - 8 (pages 15 - 18).

• All 208/230 Volt units are shipped from the factory wired

for 240 volt operation. For 208V operation, remove the

lead from the transformer terminal marked 240V and

connect it to the terminal marked 208V.

Grounding

WARNING:

The unit cabinet must have an uninterrupted or

unbroken electrical ground to minimize personal

injury if an electrical fault should occur. Do not

use gas piping as an electrical ground!

This unit must be electrically grounded in accordance

with local codes or, in the absence of local codes, with

the National Electrical Code (ANSI/NFPA 70) or the CSA

C22.1 Electrical Code. Use the grounding lug provided in

the control box for grounding the unit.

Minimum Circuit Ampacity & Maximum Overcurrent Protection

Model #

B6BW-

240VAC, 50 & 60Hz 208VAC, 50 & 60Hz

MCA MOP MCA MOP

018K-05 26.1 30 22.8 25

018K-08 40.2 50 34.8 40

024K-05 26.5 30 23.1 30

024K-08 40.6 50 35.1 40

024K-10 51.5 60 44.8 50

030K-05 26.6 30 23.2 30

030K-08 40.8 50 35.2 40

030K-10 51.6 60 44.9 50

036K-05 29.2 30 25.9 30

036K-08 43.4 50 37.9 40

036K-10 54.2 60 47.5 50

MCA = Minimum Circuit Ampacity, MOP = Maximum Over-Current

Protection

Table 2. Electrical Rating Data

Thermostat Connections

• Thermostat connections shall be in accordance with the

instructions supplied with the thermostat and the indoor

equipment. The low voltage wires must be properly

connected to the units low voltage terminal block.

• A single stage thermostat is used with this equipment

and must operate in conjunction with any installed

accessories. Typical AC and air handler hookups are

shown in Figure 3.

• The thermostat should be mounted about 5 feet above the

ﬂ oor on an inside wall. DO NOT install the thermostat on

an outside wall or any other location where its operation

may be adversely affected by radiant heat from ﬁ replaces,

sunlight, or lighting ﬁ xtures, and convective heat from

warm air registers or electrical appliances. Refer to the

thermostat manufacturer’s instruction sheet for detailed

mounting and installation information.

Thermostat

NOTE: Jumper between

W2 & E is required when

no OD T-stat is used.

Grey

White

Red R

Green

Stat

Air Handler Heat pump

Typical Heat Pump & Wall Mount Air Handler Connection

Air Handler Air

Conditioner

Typical AC & Wall Mount Air Handler Connection

Grey

White

Red R

Green

Figure 3. Typical Thermostat Connections

Conﬁ guring the Blower Speed for Multi-Speed

Units

The blower speed is preset at the factory for operation

at the same speed for heating and cooling, by using the

jumping terminal on the blower motor and connecting it

to the desired speed with both the red and black wires

connected to the jumping terminal.

CAUTION:

To avoid personal injury or property damage,

make sure the motor leads do not come into

contact with any uninsulated metal components

of the unit.

For optimum system performance and comfort, it may be

necessary to change the factory set speed. See Table 7

for airﬂ ow data.

1. Disconnect all electrical power to the unit and remove

the upper door.

2. Remove the black and red wires from the blower motor

jumping terminal. Discard the blower motor jumping

terminal.

3. Connect the heating speed wire (red) and the cooling

speed wire (black) to the desired blower speed marked

on the terminal block of the blower motor.

Table 3. Control Board Operation

Control Signal

& MODE

Operation Total KW Board Action

(EHEAT)

5 KW

Stage 1 Heat on instantly

Heat blower on after 3 second delay

10 KW

Stage 1 Heat on instantly

Heat blower on after 3 second delay

Stage 2 Heat on after 5 seconds delay

OFF

Heat stages off instantly

Blower off after 15 second delay

W & Y

(AUX HEAT)

5 KW

Stage 1 Heat on instantly

Cool blower on after 3 second delay

10 KW

Stage 1 Heat on instantly

Cool blower on after 3 second delay

Stage 2 Heat on after 5 seconds delay

OFF

Heat stages off instantly

Heat blower turns off after 40 second delay

(FAN)

ON Cool blower on after 3 second delay

OFF Cool blower off instantly

(H.P. & COOL)

ON Cool Blower on after 3 second delay

OFF Cool Blower off after 40 second delay

Minimum Heating Speed:

018 = Low

024 = High

030 & 036 = Medium

Standard 2 Speed Motors:

Terminal 4 = Hi speed

Terminal 5 = Low speed

Terminal 6 = Not Used

Standard 3 Speed Motors:

Terminal 4 = Hi speed

Terminal 5 = Med speed

Terminal 6 = Low speed

5 Speed Motor Terminals (036 units or T-Board)

Terminal M1 = Low speed

Terminal M2 = Medium Low speed

Terminal M3 = Medium speed

Terminal M4 = Medium Hi speed

Terminal M5 = Hi speed

4. Replace the upper door and secure it to the unit.

5. Restore power to the unit.

Selecting continuous low speed fan operation

(Standard Blower)

The air handler is equipped with the option of continuous

low speed fan operation. When G is energized without Y/

Y2, the air handler will operate using the Cooling speed.

With G & Y/Y2 or Y/Y2 is energized, the air handler will

operate in the selected cooling speed (including 40 sec

blower-off delay).

STARTUP & ADJUSTMENTS

WARNING:

The evaporator coil is shipped from the factory

with a nitrogen charge. Use caution when

preparing coils for ﬁ eld connections. If repairs

make it necessary for evacuation and charging,

it should only be attempted by qualified,

trained personnel thoroughly familiar with this

equipment. Some local codes require licensed

installation service personnel to service this

type of equipment. Under no circumstances

should the equipment owner attempt to install

and/or service this equipment. Failure to comply

with this warning could result in equipment

damage, personal injury, or death.

NITROGEN

HEALTH

FLAMMABILITY

REACTIVITY

0 Minimal Hazard

1 Slight Hazard

5. Inspect the unit rating plate for the proper type of

refrigerant and quantity.

6. Weigh in the proper amount of new (or reclaimed)

refrigerant.

Refrigerant Charging

The system refrigerant charge can be checked and

adjusted through the service ports provided at the front

panel. Use only gauge lines which have a Schrader

depression device present to actuate the valve.

Air Circulation

Running the Blower Continuously

Set the thermostat’s system mode to OFF and the

thermostat’s fan mode to ON. The blower motor should

run continuously. Check for air delivery at the register(s).

Ensure that there are no obstructions at the registers or

in the ducts.

Turning the Blower Off

Set thermostat’s fan mode to AUTO, the blower will shut

down immediately.

NOTE: If blower is turning opposite of arrow direction, shut

off main power to the unit and switch any two ﬁ eld wires

at the disconnect. DO NOT alter unit wiring.

System Cooling

1. Set the thermostat’s system mode to COOL and fan

mode to AUTO. Lower the thermostat’s temperature

mode below room temperature and observe that the

blower energizes. Check the air being discharged at

the register is cooler than room temperature. Verify

unit refrigerant pressures are in order. Blower should

be turning in direction indicated by arrow. NOTE: If

refrigerant pressures are abnormal and blower is rotating

in the opposite direction of the arrow, shut off main

power to the unit and switch any two ﬁ eld wires at the

disconnect. Ensure proper rotation of both compressors.

DO NOT alter unit wiring. Listen for any unusual noises.

Locate the source and correct as needed.

2. Allow the unit to run for several minutes and then set

the thermostat’s temperature above room temperature.

Verify the blower cycles off with the thermostat.

System Heating

1. Set the thermostat’s system mode to HEAT and the fan

mode to AUTO. Increase the thermostat’s temperature

above room temperature and observe that the blower

energizes. Check the air being discharged at the register

is warmer than room temperature.

2. Allow the unit to run for several minutes and then set

the thermostat’s temperature below room temperature.

Verify the blower cycles off with the thermostat.

Before You Start the Unit

Prior to start-up, complete the following inspections:

 Verify the unit is level and mounted securely to the wall.

Also make sure the air handler is properly located with

adequate clearances for servicing the unit as listed in

Table 1 (page 4).

 Check condensate drain line(s) for proper drainage.

 Verify the surrounding area and top of the unit is free

from obstructions and debris.

 Check all duct connections. Make sure the duct work

is adequately sealed to prevent air leakage.

 Check all coil connections for leaks.

 Verify that the line voltage power leads are securely

connected and the unit is properly grounded.

 Verify the thermostat is wired correctly. Make sure all

low voltage wires are securely connected to the correct

leads of the low voltage terminal strip.

 Verify the power supply branch circuit overcurrent

protection is sized properly.

 Verify ﬁ lter is properly and securely installed.

IMPORTANT: Before you start unit, perform the following

procedures to install the initial charge on units that are

factory shipped with a nitrogen holding charge:

1. Read all installation instructions ﬁ rst.

2. Purge the nitrogen holding charge.

3. Evacuate the unit to 350 - 500 microns.

4. Allow the unit to remain under vacuum for at least 30

minutes.

UNIT MAINTENANCE

Proper maintenance is most important to achieve the best

performance from a furnace. Follow these instructions for

years of safe, trouble free operation.

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

Improper servicing could result in dangerous

operation, serious injury, death or property

damage.

• Before servicing, disconnect all electrical power

to air handler.

• When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

• These maintenance instructions are primarily intended

to assist qualiﬁ ed technicians experienced in the proper

maintenance and operation of this appliance.

• Always reinstall the doors on the furnace after servicing

or cleaning/changing the ﬁ lters. Do not operate the

furnace without all doors and covers in place.

• Verify that the thermostat is properly installed and is

not being affected by drafts or heat from lamps or other

appliances.

• To achieve the best performance and minimize

equipment failure, it is recommended that a yearly

maintenance checkup be performed. At a minimum,

this check should include the following items:

Air Filter(s)

WARNING:

Never operate the furnace without a ﬁ lter in

place. Dust and lint in the return air can build

up on internal components, resulting in loss of

efﬁ ciency, equipment damage, and possible ﬁ re.

B6BW Air Handlers are supplied with a single air ﬁ lter

when shipped from the factory. It is recommended that

the ﬁ lter be cleaned or replaced monthly. Newly built or

recently renovated homes may require more frequent

changing until the construction dust has minimized. Filter

sizes shown in Table 4 are available at most local retailers.

Filters designed to remove smaller particles such as

pollen, may require additional maintenance.

Blower Compartment

Dirt and lint can create excessive loads on the motor

resulting in higher than normal operating temperatures

and shortened service life. It is recommended that the

blower compartment be cleaned of dirt or lint that may

have accumulated in the compartment or on the blower

and motor as part of the annual inspection.

Blower Fan Wheel

Inspect the blower wheel blades for accumulations of dirt

and clean if necessary. Inspect mounting nut for tightness

when done.

Blower Motor & Assembly

Inspect the blower assembly and motor mounting

brackets for tightness and corrosion. Correct deﬁ ciencies

if necessary. The blower motor contains sealed bearings

and under normal operating conditions, no maintenance

is necessary for the life of the equipment.

TROUBLESHOOTING

If the air handler fails to operate, check the following:

• Is the electric turned on?

• Is the thermostat operating properly?

• Are the blower compartment door(s) in place?

• Is the furnace disconnect closed?

• Has the circuit breaker tripped or the control board fuse

burned open?

• Are any manual reset switches open?

• Is the ﬁ lter dirty or plugged?

• Is the LED on the furnace control board constantly ON?

If not, refer to Table 5 to determine fault condition.

Red LED (AN2) Diagnostic Description

OFF Control Fault (No Power)

Flash Blower Fault

ON Normal Operation

Table 5. Furnace Control Board Fault Conditions

Model Number Filter Size

B6BW-018K

16” x 20 x 1”

B6BW-024K

B6BW-030K 20” x 20 x 1”

B6BW-036K 24” x 20 x 1”

Table 4. Filter Sizes

“B”

18 5/8

Ø3/8" K.O.

3/4

1 1/2

2 5/8

6 1/4

10 1/2

Drain

Knockout

Optional

Refrigerant

Line Entry

1 5/8

20 1/2

1 5/8

Liquid Line

2 1/8

Suction

Line

7/8

1 1/4

1 7/8

3/4

Ø3/8" Low

Voltage

Optional

Refrigerant

Line Entry

Drain

Knockout

Ø1 1/8" K.O.

Power Entry

Ø1 1/8" K.O.

Power Entry

1 5/8

FRONT VIEW

RIGHT

SIDE

LEFT

SIDE

BOTTOM

VIEW

3/4

TOP

VIEW

Primary & Secondary

Drain Connections

“A”

Table 6. B6BW Speciﬁ cations

Model

B6BW-

Refrigerant Connections

Supply Air

Duct Dimension

Suction Dia. Liquid Dia.

018K 3/4 3/8 9 x 17 1/4 36 3/8 9 1/2

024K 3/4 3/8 9 x 17 1/4 36 3/8 9 1/2

030K 3/4 3/8 9 x 17 1/4 43 1/2 9 1/2

036K 3/4 3/8 15 x 17 1/4 43 1/2 15 1/2

Figure 4. B6BW Physical Dimensions

FIGURES & TABLES

8”

7/8”

20 3/8”

10 3/16”

Ø 7/32”

(3 places)

3 1/2”

1 3/4”

.07”

MTG BRACKET

AIRFLOW DATA

Table 7. Blower Performance Data

036K

Motor Speed 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Low

936 901 891 840 789 739 688 613

Med-Low

1,160 1,122 1,087 1,046 1,001 950 899 855

Medium

1,287 1,253 1,213 1,178 1,142 1,092 1,049 1,002

Med-High

1,434 1,394 1,353 1,328 1,297 1,248 1,220 1,202

High

1,550 1,515 1,495 1,457 1,429 1,416 1,388 1,355

030K

Motor Speed 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Low

869 832 795 758 704 639 579 507

Medium

933 903 866 820 770 714 640 576

High

1,014 971 929 884 833 780 714 640

024K

Motor Speed 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Low

846 795 756 707 668 589 533 467

High

926 890 845 791 732 672 603 536

018K

Motor Speed 0.1 0.2 0.3 0.4 0.5 0.6

Low

665 645 592 521 422

326

High

769 719 656 565 459 347

NOTES:

1) Airﬂ ow is shown in cfm, +/- 5%.

2) External static pressure is shown in inches W.C.

3) All airﬂ ows are measured with ﬁ lter and with dry coil. For wet coil, subtract .1” external static pressure.

4) See unit nameplate or installation instructions for maximum recommended external static pressure.

WIRING DIAGRAMS

3. The transformer may have a dual voltage primary tap. Match the tap position

with the supply voltage used.

4. If the Internal wiring is replaced, use only 105°C copper wire of the same

gauge.

0410

FIELD WIRING

LEGEND:

LOW VOLTAGE

HIGH VOLTAGE

WIRING DIAGRAM

Wall Mount B6BW (5KW)

NOTES:

1. The blower motor speed tap connection may not be as shown. See

the Installation Instructions.

2. Disconnect all power before servicing.

710937B

(REPLACES 710937A)

¢710937;¤

CONTROL

BOARD

HEAT

COOL

EAC

HEATER

BLWDTC

YELLOW

WHITE

GRAY

RED

GREEN

TRANSFORMER

24V

230V

LIMIT

ELEMENT RELAY

ELEMENT

SUPPLY VOLTAGE

PSC

MOTOR

(3-SPEED)

1=COM

2=CAP.

3=CAP.

4=HI

5=MED

6=LOW

CAP.

MOTOR CONNECTION

SEE NOTE

NOTE:

1. B6BW-030: USE 3-SPEED MOTOR CONNECTION AS ABOVE.

2. B6BW-018 AND B6BW-024: USE 2-SPEED MOTOR CONNECTION.

2-SPEED

MTR

1=COM

2=CAP.

3=CAP.

4=HI

5=LOW

CAP.

HEAT

COOL

RED

GRAY

WHITE

BLACK

GRAY

CIRCUIT

BREAKER

ORANGE

COM

BLACK

RED

BLACK

WHITE

HARNESS

CONNECTOR

RED

WHITE

BLACK

BROWN

CONNECTOR

WHITE

RED

BLACK

BROWN

Figure 5. Wiring Diagram for B6BW-018K, B6BW-024K, & B6BW-030K (1.5, 2, & 2.5 Ton Units)

3. The transformer may have a dual voltage primary tap. Match the tap position

with the supply voltage used.

4. If the Internal wiring is replaced, use only 105°C copper wire of the same

gauge.

0510

FIELD WIRING

LEGEND:

LOW VOLTAGE

HIGH VOLTAGE

WIRING DIAGRAM

Wall Mount B6BW (8KW/10KW)

NOTES:

1. The blower motor speed tap connection may not be as shown. See

the Installation Instructions.

2. Disconnect all power before servicing.

710938B

(REPLACES 710938A)

¢710938A¤

CONTROL

BOARD

HEAT

COOL

EAC

HEATER

BLWDTC

BLACK

WHITE

GRAY

RED

GREEN

TRANSFORMER

24V

230V

LIMIT

ELEMENT RELAY

ELEMENT

SUPPLY VOLTAGE

NOTE:

1. B6BW-030: USE 3-SPEED MOTOR CONNECTION AS ABOVE.

2. B6BW-018 AND B6BW-024: USE 2-SPEED MOTOR CONNECTION.

MOTOR CONNECTION

SEE NOTE

PSC

MOTOR

(3-SPEED)

1=COM

2=CAP.

3=CAP.

4=HI

5=MED

6=LOW

CAP.

CIRCUIT

BREAKER

GRAY

ORANGE

RED

WHITE

BLACK

GRAY

2-SPEED

MTR

1=COM

2=CAP.

3=CAP.

4=HI

5=LOW

CAP.

HEAT

COOL

GRAY

COMNO

BLUE

CONNECTOR

RED

WHITE

BROWN

BLACK

RED

BLACK

WHITE

BLACK

HARNESS

BLACK

HARNESS

CONNECTOR

WHITE

RED

BLACK

BROWN

Figure 6. Wiring Diagram for B6BW-018K, B6BW-024K, & B6BW-030K (1.5, 2, & 2.5 Ton Units)

3. The transformer may have a dual voltage primary tap. Match the tap position

with the supply voltage used.

4. If the Internal wiring is replaced, use only 105°C copper wire of the same

gauge.

0410

FIELD WIRING

LEGEND:

LOW VOLTAGE

HIGH VOLTAGE

WIRING DIAGRAM

Wall Mount B6BW (5KW/036)

NOTES:

1. The blower motor speed tap connection may not be as shown. See

the Installation Instructions.

2. Disconnect all power before servicing.

¢711038®¤

711038B

(REPLACES 711038A)

CIRCUIT

BREAKER

LIMIT

ELEMENT RELAY

ELEMENT

SUPPLY VOLTAGE

CONTROL

BOARD

HEAT

COOL

EAC

BLWDTC

YELLOW

WHITE

GRAY

RED

GREEN

TRANSFORMER

24V

230V

ECM

MOTOR

COM1

U1 U2

T-BOARD

RED

BLACK

WHITE

GRAY

RELAY 1

RELAY 2

HEATER

ORANGE

BLACK

WHITE

GRAY

COM

HUM

RED

BLACK

WHITE

RED

BLACK

RED

GRAY

BLACK

HARNESS

RED

WHITE

BLACK

RED

GRAY

RED

BLACK

WHITE

Figure 7. Wiring Diagram for B6BW-036K-05 (3 Ton Units)

3. The transformer may have a dual voltage primary tap. Match the tap position

with the supply voltage used.

4. If the Internal wiring is replaced, use only 105°C copper wire of the same

gauge.

0510

FIELD WIRING

LEGEND:

LOW VOLTAGE

HIGH VOLTAGE

WIRING DIAGRAM

Wall Mount B6BW (8KW/10KW/036)

NOTES:

1. The blower motor speed tap connection may not be as shown. See

the Installation Instructions.

2. Disconnect all power before servicing.

¢711039&¤

711039B

(REPLACES 711039A)

CONTROL

BOARD

HEAT

COOL

EAC

BLWDTC

CIRCUIT

BREAKER

YELLOW

WHITE

GRAY

RED

GREEN

TRANSFORMER

24V

230V

ELEMENT RELAY

ELEMENT

SUPPLY VOLTAGE

ECM

MOTOR

COM1

U1 U2

T-BOARD

RED

BLACK

WHITE

GRAY

BLACK

WHITE

RELAY 1

RELAY 2

HEATER

BLUE

ORANGE

LIMIT

COMNO

COM

HUM

GRAY

RED

GRAY

BLACK

RED

BLACK

WHITE

HARNESS

RED

WHITE

RED

BLACK

GRAY

RED

GRAY

RED

BLACK

WHITE

Figure 8. Wiring Diagram for B6BW-036K-08 & B6BW-36K-10 (3 Ton Units)

Circuit

Breaker (60A)

Coil

Assembly

Distributor

Mounting

Bracket

Drain Pan

Heating Element

Assembly

Limit

Switch

Element Relay

Blower Housing

Transformer

Capacitor

Blower Wheel

T-Board

PCB

Board

Motor Mount

Blower Motor

Figure 9. Air Handler Components

LOCATION OF AIR HANDLER COMPONENTS

709090A (Replaces 7090900)

¢709090$¤

INSTALLATION / PERFORMANCE CHECK LIST

INSTALLER NAME:

CITY: STATE:

INSTALLATION ADDRESS:

CITY: STATE:

UNIT MODEL #

UNIT SERIAL #

Minimum clearances per Table 1

(page 4)?

YES NO

Is the unit properly installed and

leveled?

YES NO

Does condensate drain properly

in both drain tubes?

YES NO

Has the owner’s information been

reviewed with the home-owner?

YES NO

Has the literature package been

left near the appliance?

YES NO

ATTENTION INSTALLERS:

It is your responsibility to know this product better than your customer.

This includes being able to install the product according to strict

safety guidelines and instructing the customer on how to operate

and maintain the equipment for the life of the product. Safety should

always be the deciding factor when installing this product and using

common sense plays an important role as well. Pay attention to

all safety warnings and any other special notes highlighted in the

manual. Improper installation of the furnace or failure to follow safety

warnings could result in serious injury, death, or property damage.

These instructions are primarily intended to assist qualiﬁ ed individuals

experienced in the proper installation of this appliance. Some local

codes require licensed installation/service personnel for this type of

equipment. Please read all instructions carefully before starting the

installation. Return these instructions to the customer’s package for

future reference.

ELECTRICAL SYSTEM:

Electrical connections tight? YES NO

Line voltage polarity correct? YES NO

Supply Voltage: ____________________________

_______(V)

Has the thermostat been calibrated?

YES NO

Is the thermostat level?

YES NO

Is the heat anticipator setting correct?

YES NO

VENTING SYSTEM:

Is there adequate fresh air supply for

ventilation?

YES NO

Vent free from restrictions? YES NO

Filter properly installed? YES NO

Filter clean? YES NO

Flue connections tight? YES NO

Is there proper draft? YES NO

Return Air Temp: ____________________________

_______(° F)

Supply Air Temp: ___________________________________(° F)

Temperature Rise: __________________________________(° F)

PROPOSITION 65 WARNING: This product

contains chemicals known to the state of

California to cause cancer, birth defects or

other reproductive harm.

WARNING:

Speciﬁ cations & illustrations subject to change without notice or incurring obligations.

O’ Fallon, MO | Printed in U.S.A. (06/10)

Broan B6BW Installation guide

Related papers

Other documents